Arc-welding electrode



1 ()6 8 1 CROSS REFERENCE EXAMINE Patented my'a lm 2,440,941

,f UNITED STATES PATENT OFFICE 2,449,941 ABC-WELDING awe-mom:

Francis E. Garriott, West Allis, Wis asslgnor to Ampco Metal, Inc., Milwaukee, Wis, a corporation of Wisconsin No Drawing. Application August 19, 1946, Serial No. 691,653

1': Claims. 219-8) This invention relates to an arc welding elecclung] carbonate. a metal degxiggr such as ierrgtrode of low melting point copper base alloy such chro um or err0'- 1 a a as brass, Phosphor-bronze, silicon-bronze and 's'fcfi'as a! a er suc as sodium the like.

The invention more particularly involves the e l ngl 'e composition or a covering for the metal core togethrJan'dthen the are added of such an electrode which greatly facilitates the to make a slurry for dipping of the core rods or welding operation and the production of sound a P p extrusion n the rods. T

welds in iron, copper and nickel base alloys. sistency may be adiusted by additions of gter One of the principal objects of the invention f desired, for pp F extrusion 8 P 0 fis to provide an electrode of copper base alloy the w um silicate may be replaced by of the type referred to which is capable of use wfimdssn cate. Generally .4 pa 0 in all positions: vertical, overhead and downpow soum :1" e is equivalent to about hand, and for single and multiple pass weldone part of wet sodium silicate (40-42 Baum). ing, particularly with direct current, One example of covering composition that has Another object of the invention is to provide been found to be very satisfactory f r tin bronze an electrode of copper base alloy of the type reelectrodes is as follows: ferred to and which may be employed in the welding of iron. copper and nickel base alloys and the like. 1 Wt rfi'ififfiz Another object is -to reduce the size Of the globular transfer of metal acrosstn 1 the arc, t:Ehereby gluon-spun 0.1 1;: 1

producing a softer arc wi ess spat r and greater eiliciency of deposit. i'r'b1.($%::m .22: 33 it Another object is to provide a covered copper 2 $159 (M :8 2:

base alloy electrode in which the fluidity and Bentonite 5 1-0 physical characteristics of the slag is correlated g fmt ,g

to the metal deposit to produce a deposit oi Sodium Silicate et'fiiaaumanaii 100 smooth bead contour, feather-edging properly into the ini base metal with m of under Numerous modifications oi the above coverin cutt andsurieit rardl i ac pt mg ess of p051 have been employed for applying to Phosphor Another object is to provide a gaseous shield of bronze core was 17mg an mutants from a reducing character that protects the weld metal 5% to and wide'vmety of smcon bmnze from ondation and which reduces the tendency brass suchmodmcaflons depend upon the core wire composition and are generof zinc in brasses to eiiervesce.

An th r ob act t ally based upon the melting point and electrical j is 0 pm de a m for the conductivity of the core wires.

weld which readily floats out impurities from p the weld pool and is friable and easily removed. specific i are illustrated in the Another object is to provide a covering which table does not require close tolerances in covering thickness and which is relatively insensitive to Composition No. variations in composition of the core wire and in 7 the welding current. 1 1 2 a 4 a s sm fi. lfitisianrnvigsj I I/ may be applied by ithe; dippi gr ;e;t1;u si0n m m 114 114 no gm tfila rmia ns snseammg g g 3 g gig. so so ac other object is to provide a covering for an :8 fig electrode oi the alloys referred to which will not g .3. 2g 2g 3g interfere with re-striking oi the arc aiter the 4 8 8 8 electrode is partially consumed. i 2 -3. The covering comprises, in general, fluorides m m oi alkaline earth metals, preferably ofcalc um I V I 9 Et figs m N .l'he bentonite is employed for extruded cov fluxed met cipalmetals of the deposit .against oxide incluerings, and where the coverings were to be dipped SiOz was substituted for it. "The alpha flock should be of about 200 mesh fineness or dipped coverings and about 40 mesh fineness for extruded coverings.

The websc diilmssilicate was.42 Baum. In general the cevering should-have a. melting point at which it disintegrates on the rod, somewhere related to the melting point for the metal of the rod. If the melting point or disintegrating point of the covering is at too .highaxem- I perature the covering will.ex tnd down.beyond the tip of the metal core and surround the .arc

even to the extent of possible extinction of the arc.

If the melting or disintegrating pointeof the covering is at too low a temperature the covering will melt off ahead of the arc and leavegthermctal core bare at the tip, thereby failing to protect the metal as it melts and transferred across the -arc. Most .copper alloys of the types. referred .to hereinare not suitable forbare mire welding. Where the core wire is bare atthetip the metal transfers across the arc in drops or large globules .and causes sputtering pf .the arc.

The desirable-covering isone which will iorm a small crater aroundthe. arcingtip of. the metal .core .and thereby physically protect .iahe ,metal Jrom contamination during melting and expu sionirom the tip. The metal is then free untransfifer .acrossthenrc in a fine spray and the .arc

,action is smooth, thereb providing a more veifiiicient deposit with lessspatter.

lngeneral .the coveringcomposition may. con- .tain ;the several ,ingredients in -the vfollowing ranges:

Parts by weight 'fluorspar fGaFz) 14010200 Cryolite .,f 90to 30 'FeCr to 25 Marble (CaCOa) lOto 50 Magnesite (MgCQa) $015017!) Silica 110170 Bentonite 1-u-. 4 :1 Alpha Flock (Ce1lulose) Alto Water added to provide the proper consistency for application to the rod.

' Hie .aflu d s a e :in beati out ahezwiide uof cop er, sil co 73 313 item the -weld 1 deposit, andalso :serve to adjust :the me t n pointer theco eri and be ete sion net-h aled if adhi he sm ltine p int isd isired a inth .fl s .z ho phor :bronze sad. the fiuorspar content isgincreased. if in :lower smeltin point -is desired :io He res a fluorspar content is decreased angljghe content increased. In some cases sodium fluoride may be substituted for the cryolite.

'I'he ferro-chromium serves as a deoxidizer and controls to some extenhthe surface tension of the slag. Other term-alloys may be substituted for "ferro-cromiuin, "Such as ferro-columbium, ferrom n n e -t1t n f denum. =ierro-silicon,g powdered iron and thelike. The :ferro-alloys when combined withgajflliflsride type of covering s'erye .to provide a oxi e a d protect the 12.1f

. I Either-nimbl 212mm na lqonat may .be usedin ereba ne hlx .1 q st bi iz ng h rea additionally improving the surface tension of the slag and adjusting the melting point of the covering.

The magnesite or magnesium carbonate aids appreciably in stabilizin the arc and is important in controlling the arc penetration and in p oducin airiable slag .bavingpnoper surface #tension haracm'istic-s. r j ja The silica and bentonite are slag forming ingredients and are added to provide a more friable 10 slag and control the surface tension of the slag. mefreeailica combines with some of the metal nxidesaud Jemoves the same to the resultant slag wmfltflsgthereby aiding in the fiuxing of .tbe'wemaiemsit. 1 The alpha flock or cellulose decompose in the (cu-tenor are-covering to form a reducing gas which permeates the arc region and tends to pro- .teet-the metal in the arc stream against contar'nination by oxygen and nitrogen of the air. The cellulose provides'a more uniform crater.for the. covering attheti .o he el od a p e- .v ents lfinger nailingofthe covering. Other organic or carbonaceous materials may be substit uted f or a.,nart or all of the alpha flock,1i. e.imazsterialssuch a d inve u rs, .d

'trine, carbon and t'roleum coEe. t era. was .68, nor l V um silicate may e used asthe binder. They e ermine the .um- .01 characteristiosionthe.rodandalso aid in conzotrollingjthesuriace tension of the s1ag. Where sodium .,silicate is JJsetL the ,proportionate amountspfidryiqppwdered) silicateand of wet smcatemaybe .varieddependin'g up n the meth- 0 of pp cationnuheeovering tdthe core wire. 85 .fl'hecovering mixtureshomd nontain moreof the .dryssodium silicate and iess-of the avetsodium lsili ateiioriusain .theextrusionprocesaand vice- Amrsa iormsedn Jhe..dinn1n process.

The thickness of the covering on the.rod.will 4o .va y .with thein'ocesaofv application and should .hebetween .ahoiit .;0I5".and A1252. .The actual ewei htlofthacnvering asnompared to 'thatofthe rod may vary dependingiipon thessiae oi thecore vgire. ln aeneralithelcoaiing wilibe from about, 1:0 .aboutzzpernenaof thatotal :weight. oLthe pmdiihesmallenper'cant .beingpresent with large eoorewires oi abouhohe-auarter inchindiameter sand .the larser per rCBn-t being present with core ptahcuhone-eiehthinchand less mumm- .e Bl- The deposit obtained with the present elecxh'QdSJSfi-QISE-flfliSQU-Dd, and is free frominter- ,naLporositynndslag inclusions. .Ithas improved nhysical pronertiearesultingzfromthe use of the covering.

-I 'he addition .nf rellulose to etheifiuonide slag of marine tends to reduce oxidation of the metal-as .ihpasses through the are, Just enough eflect wsoundideposit that can rbe efficiently mixed 'by rthe slag. .ii'he -.cellulcse additionally A imals-the wavering enter and aids in produc- 54 StBBidy-mn. The Ierro-Mloydeoxidiaes the melt and facilitates the flexing faction .of the Ihc MWEiWIOFfliQ m mposit o! varim5 fl-HQRS which would met 719913171813?- torily deposited heretofore.

inflows-embodiments .of the invention ma be mployedswifliin thessoope pf *thenccompanying 19mm.

Iclaim: r

.qA :eovering :f or iB- .eopperrbase alloy-electrode pf :the class described fluoride slag p ducing ingredients and flawbinder, --with =the fluorides selected irom alkaline earth metal fluo- IOfi'b'i cla m rides and containing principally calcium fluoride, and an small metal carbonate in an amount su fflcient to improve the surface tension of the alas. the ingredients being proportioned to provide a covering having a low disintegration temperature correlated to the melting point oi'the metallic core of the electrode.

2. A covering for a copper base alloy electrode of the class described comprising fluoride slag producing ingredients and a binder, with the fluorides selected from alkaline earth metal fluorides and containing principally calcium fluoride, and a magnesium compound to increase the arc penetration and improve the physical properties of the slag, the ingredients being proportioned to provide a covering having a lowdisintegration temperature correlated to the melting point of the metallic core of the electrode.

3. A covering for a copper base alloy electrode of the class described comprising fluoride slag producing ingredients and a binder,. with the fluorides selected from alkaline earth :metal fluorides and containing principally calcium fluoride, and a ferro-alloy deoxidizer to facilitate the fluxmg action of the alas, the ingredients being proportioned to provide a covering having a low disintegration temperature correlated to the melting point of the metallic core of the-electrode.

4. A covering for a copper base alloy electrode of the class described comprising fluoride slag producing ingredients and a binder, with the fluorides selected from alkaline earth metal fluorides and containing principally calcium fluoride, and a carbonaceous constituent to improve the burn-oi! characteristics of the covering and prevent excessive oxidation of the metal transienring through the arc, the ingredients being proportioned to provide a covering having a low disintegration temperature correlated to the melting point of the metallic core of the electrode.

5. A covering for a copper base alloy electrode of the class described comprising fluoride slag producing ingredients and a binder, with the fluorides selected from alkaline earth metal fluorides and containing principally calcium fluoride, a ferro-alloy deoxidizer to facilitate the fluxing action of the slag, and a carbonaceous constituent to improve the burn-oil characteristics of the covering and prevent excessive oxidation of the metal transferring through the arc, the ingredients being proportioned to provide a covering having a low disintegration temperature correlated to the melting point of the metallic core of the electrode.

6. A covering for a copper base alloy electrode of the class described comprising fluoride slag producing ingredients and a binder, with the fluorides selected from alkaline earth metal fluorides and containing principally calcium fluoride, calcium carbonate in an amount suflicient to improve the surface tension of the sla and a magnesium compound to increase the arc penetration and improve the physical properties of the slag, the ingredients being proportioned to provide a covering having a low disintegration temperature correlated to the melting point of the metallic core of the electrode.

7. A covering for a copper base alloy electrode of the class described comprising fluoride slag producing ingredients and a binder, with the fluorides selected from alkaline earth metal fluorides and containing principally calcium fluoride, calcium carbonate in an amount sufficient to im- 6 and improve the physical properties of the slag. and a ferro-allcy to facilitate the fluxing action of the slag, the ingredients being proportioned to provide a covering having a low disintegration temperature correlated to the melting point of the metallic core of the electrode.

'8. A covering for a copper base alloy electrode of the class described comprising fluoride slag producing ingredients and a binder, with the fluorides selected from alkaline earth metal fluorides and containing principally calcium fluoride, calcium carbonate in an amount sufficient to improve the suriace tension of the slag, a magnesium compound to increase the arc penetration and improve the physical properties of the slag, and a cellulose constituent to improve the bumoif characteristics of the covering and prevent excessive oxidation of the metal transferring through the arc, the ingredients being proportioned to provide a covering having a low disintegration temperature correlated to the melting point of the metallic core of the electrode.

9. A covering, for a copper base alloy electrode of the class described comprising fluoride slag producing ingredients and a binder, with the fluorides selected from alkaline earth metal fluorides and containing principally calcium fluoride, calcium carbonate in an amount sufllcient to improve the surface tension of the slag, a ferroalloy to facilitate the fluxing action of the slag, a magnesium compound to increase the arc penetration and improve the physical properties of the slag, and a cellulose constituent to improve the burn-oil characteristics of the covering and prevent excessive oxidation of the metal transferring through .the arc, the ingredients being proportioned to provide a covering having a low disintegration temperature correlated to the melting point of the metallic core of the electrode.

10. A covering for a copper base alloy electrode of the class described comprising principally the following ingredients in the composition ranges indicated in parts by weight: fluorspar 140 to 200, cryolite to 30, ferro-alloy 5 to 25, marble 10 to 50, magnesite 30 to 70, silica 10 to 40, and a binder of sodium silicate constituting from to 150 parts.

11. A covering for a copper base alloy electrode of the class described comprising principally the following ingredients in the composition ranges indicated in parts by weight: fluorspar to 200, cryolite 90 to 30, ferro-alloy 5 to 25, marble 10 to 50, magnesite 30 to 70, silica 10 to 40, a binder of sodium silicate constituting from 100 to parts, and ben'tonite up to about 5 parts to facilitate extrusion of the composition upon the rod.

12. A covering for a copper base alloy electrode of the class described comprising principally the following ingredients in the composition ranges indicated in parts by weight: fluorspar 140 to 200, cryolite 90 to 30, ferro-alloy 5 to 25, marble 10 to 50, magnesite 80 to 70, silica 10 to 40, a binder of sodium silicate constituting from 100 to 150 parts, and cellulosic material up to about 25 parts.

13. A covering for a copper base alloy welding electrode of the class described, comprising principally the following ingredients in the composition ranges indicated in parts by weight: fluorides of alkaline earth metals to 290 principally in the form of calcium fluoride, a ferroalloy deoxidizer 5 to 25, an alkali metal carbonate 40 to 120 and a silicate binder therefor.

MAMIM 14. Anovering for a copper'base alloywe'lding de'ctrodeoi the class described,-comprisingprincipally the following ingredients inthecompm sitionranges indicated in parts'by weight: :fluorides of alkaline earthmetals '1'70 to290principally in the form-of calcium fluoride-a 'i'erroalloy deoxidizer '5 to 25 principally in the form of term-chromium, an alkali metal carbonate 40 to'l20 principally in the formnf calcium carbonate, and a silicate hinder therefor.

'15. A covering for a copper-base alloy welding electrode of the class described, comprising-principally the-following ingredients in the composition rangesindicated in parts by weight: fluorides-of alkaline earth metals selected to correspond to afluorspar and cryolite mixture-having from 140 to200 parts of fluorspar and'90 to '30 parts of cryolite, arferro-alloy-deoxidizer corresponding to a-ierro-chromium content of to 25'parts,'an alkali metal carbonate content corresponding to a mixture of calcium carbonate and magnesium carbonate having from to 50 parts of calcium carbonate and from -30'to 70 parts of magnesium carbonate, and a binder therefor.

16. A covering for a. copper base alloy welding electrode of the class described, comprising principally the following ingredients in the composition ranges indicated in parts by weight: fluorides of alkaline earth metals selectedto correo spond to a*fluorspar and -cryolite mixture having from 140 to 200 parts of fluorspar and 90 .to ill-parts of cryolite, a ierro-alloy deoxidizer corresponding to a-ferro-chromium content of 5 to parts, an alkali metal carbonate content-corresponding to a mixture -ofcalcium carbonate-and magnesium carbonate naving'irom -10rto 50 parts m of calcium earbonateand from to'loparts'of magnesium carbonatepa carbonaceous ingredient corresponding to acellulosecontent up to about partsmilica "10 to and aoinder-thereior. V

' FRANCIS E. GARRIO'IT.

REFERENCES or'mn The following references are of recor'din the file'of this patent:

Um'mD'srATEs PATENTS Number Name Date 12,320,677 iewm '%7une'1,-l943 

